Brake Master Cylinder (W/O Vsc) -- Installation |
| 1. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD |
- NOTICE:
- The brake booster interior must not be a vacuum when adjusting the booster. Stop the engine and depress the brake pedal several times until there is no vacuum in the booster.
- HINT:
- Adjust the booster push rod when the master cylinder is replaced with a new one. Adjustment is not necessary when the master cylinder is reinstalled and the booster is replaced with a new one.
Set SST on the master cylinder and lower the rod of SST until it just touches the piston.
- SST
- 09737-00013
- HINT:
- SST 09737-00012 can also be used.
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Apply chalk to the flat of the rod of SST. Turn SST upside down and measure the clearance between the brake booster push rod and SST.
- Standard clearance:
- 0 mm (0 in.)
If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.
If the clearance is not as specified, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.
- SST
- 09737-00020
- NOTICE:
- Check the push rod clearance again after adjusting.
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| 2. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY |
Apply a light coat of lithium soap base glycol grease to the 2 new grommets and install them to the master cylinder.
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Install the reservoir with the screw.
| 3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY |
Install a new O-ring to the master cylinder.
Install the master cylinder and bracket (with 3-way) to the booster with the 2 nuts.
- Torque:
- 15 N*m{153 kgf*cm, 11 ft.*lbf}
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Using a union nut wrench, connect the 5 brake lines labeled C to the master cylinder and 3-way.
- Torque:
- 15 N*m{155 kgf*cm, 11 ft.*lbf}
- NOTICE:
- Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).
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Connect the brake fluid level warning switch connector labeled B to the master cylinder.
for Manual Transmission:
Connect the clutch reservoir tube labeled A to the master cylinder.
| 4. FILL RESERVOIR WITH BRAKE FLUID |
- Fluid:
- SAE J1703 or FMVSS No. 116 DOT 3
| 5. BLEED AIR FROM BRAKE MASTER CYLINDER |
- HINT:
- If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.
Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
Slowly depress and hold the brake pedal.
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Cover the outer holes with your fingers, and release the pedal.
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Repeat the 2 previous steps 3 or 4 times.
Using a union nut wrench, connect the 2 brake lines to the master cylinder.
- Torque:
- 15 N*m{155 kgf*cm, 11 ft.*lbf}
- NOTICE:
- Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).
| 6. BLEED AIR FROM BRAKE LINE |
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Remove the bleeder plug cap.
Connect a vinyl tube to the bleeder plugs.
Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.
When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.
Repeat the 2 previous steps until all the air in the brake fluid is gone.
Tighten the bleeder plug.
- Torque:
- 11 N*m{110 kgf*cm, 8 ft.*lbf}for front brake
- 10 N*m{102 kgf*cm, 7 ft.*lbf}for rear brake
Install the cap.
Bleed air from the brake line for each wheel by repeating the above procedures.
| 7. BLEED AIR FROM CLUTCH LINE (for Manual Transmission) |
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Remove the bleeder plug cap.
Connect the vinyl tube to the bleeder plug.
Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.
At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.
Repeat the previous 2 steps until all the air in the fluid is completely bled out.
Tighten the bleeder plug.
- Torque:
- 11 N*m{112 kgf*cm, 8 ft.*lbf}
Install the bleeder plug cap.
Check that all the air has been bled out of the clutch line.
| 8. CHECK BRAKE FLUID LEVEL IN RESERVOIR |
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Check the fluid level and add fluid if necessary.
- Fluid:
- SAE J1703 or FMVSS No. 116 DOT 3
- HINT:
- Add fluid to a level between the reservoir's MIN and MAX lines.
| 9. CHECK FOR BRAKE FLUID LEAKAGE |